Alternator-rectifier electrical generating system



March 10, 1959 w. M. HALLIDY ALTERNATOR-RECTIFIER ELECTRICAL GENERATING SYSTEM Filed July 19, 1955 3 Sheets-Sheet 1 NGE INVENTOR. WILLIAM M. HALLIDY BYZ ,Q F@ 7/ J ATToKRN s March 10, 1959 w. M. HALLIDY 2,877,402

ALTERNATOR-RECTIFIER ELECTRICAL GENERATING SYSTEM Filed July 19, 1955 3 Sheets-Sheet 2 p W L n n 84 5 Ju uu l J1 UUJI o CYCLES x O X.

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WILLIAM N. HALLIDY AT TORN March 10, 1959 w. M. HALLIDY 2,877,402 ALTERNATOR -RECTIFIER ELECTRICAL GENERATING SYSTEM Filed July 19, 1955 3 Sheets-Sheet 5 ATTORNEYS United States Patent' AL'I'ERNATOR-REC'I'IFIER` ELECTRICAL GENERATING SYSTEM William. M. Hallidy, Lakewood, Ohio, assignor. to` The Leece-Neville Company, Cleveland, Ohio, a corporation of Ohio ApplicationJuly 19,1955, Serial No. 522,911, 9 Claims.l (Cl. S20-28) This4 invention relates to generating systems of the alternator-rectifier type, and more particularly, tor the control of the load relay employed in such a system for Patent 2,789,265 granted April 16, 1957.

In generating systems of the alternator-rectifier type, which include a storage battery to be charged as a portion of an external load connected with a polyphasealternator, the load circuit is usually connected with the direct current terminals ofthe power rectifier through a load relay. In such a system it is desirable that the load relay be under the control of the alternator so that the relay will close and open automatically in response to a predetermined. terminal voltage output value of the alternator.

The most economical way of automaticallyclosing vthe load relay in response to the operation of the alternator, would. be to energize the load relay magnet coil by a portion of the direct current outputv of the power rectifier, but when the load relay coilI is energized in. this way, the opening ofthe load relay is no longer under the control ofthe alternator. This results fromv the fact that as soon as'the relay contacts are closed by the alternator output voltage, its magnet-coil will then be subject toenergization from the battery and will hold thecontacts lclosed after the output voltage drops to zero value.

To accomplish the desired automaticcontrol of the load relay by the alternator, it has` heretofore been necessary to provide the system with .an auxiliary or. control rectirierr as is shownsin United States Patent No. 2,'646- 543, granted July 2l, 1953, for connecting the load .relay magnet coil with the alternator. Such. a control rectifier has added considerably to the cost .of generating systems of this kind.

As. its principal object, the present invention therefore provides a novel generating system of the .alternator-rec? tier type inwhich the'above-explained cost disadvantage is overcome, and in which the closing and opening ofthe load relay is automatically responsive tothe opera.- tion of a: polyphase alternator by the load relay magnet coil being .connected fwithphase. windings of the alternator through control resistors.

Another object is to provide anovel alternator-recti-r fier generating system nfwhich they load relay magnet coil is energized from the phase windingsof the alternatory through such control resistorswhile a portion ofk the powerrectifieris .utilizedasa blocking means to prevent energization of the relayl magnet coil from the storage battery of the external load` circuit..

Still another object is to provide such a generating. systemvinawhichthe energization of theA load relaymagnet coil.l from :.th'e phase: windings `and y through such. control resistors@ also? takes; place` through one.V portion of` the power rectifier, whichisi preferably a multiple-ce1l.full-. wave rectifier, while anotherI portionof thepowerrec-z tier'prevents energzation of the relay magnet coil from the battery ofthe load circuit.

Additionally, this invention provides such an alternatorrectifier generating lsystem in which the magnet coil of the load relay has one end thereof connected with phase windings'of the alternator through control resistors and has its other end connected with one ofthe direct current-load terminals of the power rectifier, and in which the connection for such other end of the magnet coil can be veither a grounded orungrounded connection.

Otherobjects and advantages. ofthis invention willbe apparent in the following detailedV specification and in lthe:l accompanying` sheets of drawings forming a part thereof and in which:

Fig. 1 is a wiring diagram illustrating an alternatorrectifier. electrical generating system embodying the pres ent invention, and` in which theload relay magnet coil is connected with the phase windings ofthe alternator through control resistors;

Fig. 2 is al schematic wiring diagram of the generating system of Fig. 1;

Fig. 3"is a graph illustrating the wave form obtained in the generating system of Fig. 1 for the energizing current supplied to the load relay magnet coil;

Fig. 4 is a schematic wiring diagram illustrating the same. generating systemy as Fig. 1 but as a negativeground form of the system;

Fig. 5 lis a schematic wiring diagram illustrating a generatingsystem similar to that of Figs. l and 2, but em; ploying a different circuit. for the load relay magnetcoil;`

Fig. 6 is a graph illustrating the wave form obtained in the generating system of Fig. 5 for the energizing current supplied to the load relay magnet coil;

Figs. 7 and 9 are schematiewiring diagrams'illustrating generating systems similar to those of Figs. 2 and 5, re; spectively, but in which a smaller number of control resistors are used in the load relay control circuit; and

Figs. 8 and 10 are graphs illustrating the wave form for the relay magnet coil current in the generating systems of Figs. 7 and 9 respectively.

As one practical embodiment of this invention, Fig. l illustrates a generating system 10 having an. alternator 11 connected with an external direct current load through a main or power rectifier 12, and through a loa'd conductor 13 and a common ground G. The external load includes a storage battery 14'which is connected with the power rectifier 12 by the conductor 13 through the series contacts 15 rand .16'of a load relay 17.

Other. components of the generating system 10 include voltage and current regulators 18 and'19 of the relay type for controllingthe operation of the alternator 11, and a control unit 20 serving4 the' load relay 17.v These various components of the generating system 10 and their functioningtherein .will be further described hereinafter.

Th'ealternator 11 is here shown as being a three-phase alternator having a field winding 21 and inductor windings 2223 and 24. The inductor windings 22, 23 and 2.4are hereshown as being Y-connected.

The power rectifier 12'is a three-phase full-wave multiple-cell rectifier of the dry-plate type and is here shown as having three parallel circuit arms 27, 28 and 29 with whichtheinductor windings 22, 23 and 24 ofthe alternator 11v are connected, respectively. Each of the circuit arms 27, 28r and`29 has a pair of rectifier cells 30 and 311therein and." the connection of each inductor winding ofthe alternator with its associated circuit arm. of. the rectifier s madezat a point between such pair of rectifier cells.

. The generating system 10 isr here shown as beinga systemof these-calledpositvesground type in whichthe positive terminal 33 of the storage battery f14lisconuected to the common ground G by the conductor 35. The

power terminals 36 and 37 of which the terminal 37 is a positive terminal and is connected to the common ground. The negative direct current terminal 36 of the power rectiiier 12 is connected with the negative terminal 38 of the battery 14 through the load conductor 13.

The load relay 17 is a conventional load relay comprising a magnet frame 40 having an energizing coil 41 thereon, and an armature 42 carrying the movable switch contact 15 and responsive to the energization of the magnet coil 41. The load relay contacts 15 and 16 are rectifier 12 further includes direct current load normally open for disconnecting the battery 14 from the alternator 11 and such open condition of these contacts is normally maintained by the tension spring 43. The energization of the load relay magnet coil 41, as provided by this invention, will be explained hereinafter.

The voltage regulator 18 can be of a conventional form and is here shown as being of the kind disclosed in and covered by United States Patent 2,520,689, granted August 29, i950. The voltage regulator 18 comprises a frame 55 having a voltage magnet coil 56 thereon, and a vibratory armature 57 carrying movable switch contacts 58 and 59 which cooperate, respectively, with upper and lower stationary contacts 60 and 61. A tension spring 62 effective on the armature 57 urges the same toward a normally closed condition for the cooperating contacts 58 and 60. The voltage regulator 18 also comprises a ballast resistor 63 in series circuit with the magnet coil 56, a point resistor 64 in shunt relation to the upper pair of cooperating contacts 58 and 60, and a secondary resistor 65 rwhich assists the ballast resistor 63 in controlling the energization of the magnet coil 56.

The current regulator 19 can also be a conventional form of such a device and is here shown as comprising a magnet frame 67 having a series magnet coil 68 thereon, and a vibratory armature 69 carrying a movable switch contact 70 which is urged toward a normally closed engagement with a stationary contact 71 by the action of a tension spring 72 on the armature.

The point resistor 64 of the voltage regulator 18 also serves as a point resistor in shunt relation to the cooperating contacts 70 and 71 of the current regulator 19. The point resistor 64 and the voltage and current regulator contacts 58, 60, and 70, 71 are in the iield circuit of the alternator 11 and control the energization of the tield winding 21 in accordance with the terminal voltage and current output values of the alternator, as is understood by those skilled in this art.

The lower stationary voltage regulator contact 61 is connected with the common ground G and the upper stationary voltage regulator contact 60 is connected with the movable current regulator contact 70 by the conductor 73. Although the functioning of the voltage and current regulators 18 and 19 in controlling the operation of the alternator 11 is generally understood by those skilled in this art and need not be here described in detail, it can be mentioned, however, that whenever the contacts 58 and 60 of the voltage regulator and the contacts 70 and 71 of the current regulator 19 are in a closed condition at the same time, the point resistor 64 is short-circuited out of the energizing circuit of the tield winding 21. Whenever the voltage regulator contacts 58 and 60 or the current regulator contacts 70 and 71 are open, the point resistor 64 is in series circuit with the tield winding 21. Likewise, it can be mentioned that whenever the lower voltage regulator contacts 59 and 61 are closed, the iield winding 21 is substantially short-circuited for collapsing ythe iield excitation. l

In accordance with the present invention, the load relay magnet coil 41 is energized from the alternator 10 through the control unit 20 and through a portion of the power rectifier 12. The control unit 20 is a resistor unit and will be described next.

The control unit 20 comprises a group of resistors, in this instance three such resistors 44, 45 and 46, which are disposed in a parallel relation in the energizing circuit of the load relay magnet cfil 41. The resistors 44, 45 and 46 are simple resistors of a suitable resistance value and are substantially identical.

The three control resistors 44, 45 and 46 are connected on one side thereof with the inductor windings 22, 23 and 24 of the alternator 11 by the conductors 50, 51 and 52, respectively. The control resistors 44, 45 and 46 are connected on the other side thereof with a commoncontrol current terminal 47.

The energizing circuit of the load relay magnet coil 41 is connected with the alternator 11 by one end of the relay magnet coil, being electrically connected directly with the common control current terminal 47 of the unit 20 by the conductor 75. The other end of the magnet coil 41 is connected with the direct current terminal 37 of the power rectifier 12 through the conductor 76 and the common ground G.

From the construction and functioning of the components of the generating system 10 as thus far described, it will be seen that when the alternator 11 is not being driven, the load relay contacts 15 andv 16 will be held open by the spring 43 to thereby disconnect the battery 14 from the alternator. When the alternator is placed in operation as by the starting of the vehicle driving engine, the load relay magnet coil 41 will be energized by the alternator through the control unit 20 and through a portion of the power rectifier 12 to thereby automatically close the load relay contacts 15 and 16 and connect the external load in circuit with the alternator through the power rectifier.

To explain further how the load relay magnet coil 41 is suitably energized from the alternator through they control unit 20 and the power rectifier 12, it is pointed out that when the alternator is placed in operation current ows from the phase windings 22, 23 and 24 through the rectifier cells 31 to the direct current load terminal 37 and then through the common ground G and the conductor 76 to the load relay coil. From the coil 41 the current ows through the conductor to the common terminal 47 of the control unit 20, and then back to the phase windings of the alternator through the resistors 44, 45 and 46 and the conductors 50, 51 and 52.

From the energizing circuit as just above traced for the load relay magnet coil 41, it will be seen that the cells 31, 31b and 31e of the power rectier 12 are included in this circuit as conducting cells and that the cells 30E, 30 and 30 are serving at the same time as blocking cells. These blocking cells prevent energization of the magnet coil 41 from the storage battery 14 when the load relay contacts 15 and 16 have been closed in response to operation of the alternator.

From the energizing circuit above described for the magnet coil 41 of the load relay 17, it will now also be seen that by the use of the relatively simple and inexpensive resistor 20 in conjunction with the power rectifler 12, satisfactory energization of the load relay under the control of the alternator 11 is obtained. This satisfactory energization of the load relay magnet coil from the alternator 11 with relatively reduced cost is further illustrated by the graph of Fig. 3 in which the wave from curve 77 illustrates the voltage characteristic of this energizing current. The curve 77 represents two cycles of operation of the alternator 11 and was plotted relative to the zero value horizontal axis OX in accordance with voltage values shown by an oscilloscope to exist in the load relay magnet coil circuit during the functioning of the generating system 10.

The schematic wiring diagram of Fig. 4 showsan alternator-rectifier generating system 10a which is substantially the same in structure and function as the above-described generating system 10 but which is a negative-ground type of system. In this negative-ground with the phase-windingsV 'Energization of theloadbeen closed, by the cells 'rectifier 12 which then actas blockingicells.

:isenergized from the zcuit which extends through thecontrol resistors of the 1.unit 20 and through The systems-85 and 86 differ fromthesystems 10 and 80, however, inthat the unit `20 comprisesfatrelatively smaller other side thereof 76and through vthe vcommon are designated 33n and 38a.

In the system 10', all:ofthe-rectifierfcellsofthepower :rectifier 12 are shown`in=a-tpositon reversed ffromFig. '.2

inasmuch as this system is of the:negativegroundtype The wave form lof the energizing current of l:the fload ire- `lay magnet coil 41 in the negative-ground :system fof TF ig.

.4` is the `same as is representedbyithe curve lL7-ofthe `;:graph shown in Fig.'3. A

Fig. of the Ydrawings -isbowsfan :alternator-rectifier generating system 80 `which is similar tothefgenerating :system 10 :of Figs. l and2 and similar tothegenerating system 10a of Fig. 4,

in ,that fthe energizing Acircuit rfor 4the magnet coil 41ofthe\loadfrelay l17is'connectedwith the alternator 11 through the control unit 2) and through sa portion of the power rectifier 12. However, in the generating 1system T80, one end of the energizing `circuit for fthe load relayl magnet coil 441 lis directly connected with the 'control unit 20 by the conductor 1'82. "'lhefotherend 'of this energizing circuit i is connected :with the Y alternator "through a portionof the load conductor and/through the :conductor r83. TheV portion `of load conductor through fwhich this magnetcoil circuit extends is represented .in 'the schematic diagram ofIFig. 5 'bytthe circuit arm 13 In the generating system'80of Fig. "5 it 4will-also'be seen that portions ofrthe power.rectifer112rare'included in the energizing circuit for theload relay`magnet coil 41, in that the cells 30a, 30bvand 30 arein :series circuit and thelload/relay magnet coil. relay .coil from the battery-'14 is prevented when the load relayrcontactsl-S and l6have 319, 31bfand31,of the power fFig. 6 is agraph inwhichrthe'curveL-84 vrepresents the -wave form of the energizing: current obtained in=the load .-relay coil 41 of the generatingsystem 80. The-curve1l84 .is substantially the same'as the curve177 shown in fFig. 3

for the system .10.

sFigs. 7 and 9 of the drawings:.showigenerating systems I'-85 and'86 which are similar to the systems :10 andf80 of Figs. l and 5, respectively, in that the load relay coil-41 alternator 1'11.by `an yenergizing cirportions of 2 the power rectifier v12.

number of the control resistors and .is-shown in these systems as consisting of two such control resistors 44 and 46 vdisposed inparallel yand fhaving'a common terminal 47 on one side thereof and-being-,connected on the with the phase windings 22and-24 of the alternator through the conductors 50 and 52.

In the generating system '85, oneend. of the load/relay coil 41 is Vconnected directly with they common terminal 47 of the control unit 20 by theconductor 75 and the other end is connected with the direct current load terminal 37 of the power rectifer'lZ through the conductor ground'G. Thus in the system 85, the cells 31a, 31b and 31c of the power rectifier 12 are conducting cells and are included in the load relay coil circuit in series with the phase windings, whereas the cells 30a, 30b and 30c are blocking cells which prevent energization of the load relay coil from the battery 14 when the load relay contacts 15 and 16 have been closed.

In the generating system 86, one end of the load relay coil 41 is connected with the common terminal 47 of the control unit by the conductor 75 and the other end of this coil is connected with the power rectifier through a portion of the load conductor 13 which is represented in the schematic wiring diagram of Fig. 9 by the conductor arm 13a. Thus, in the generating system 86 the `Slt-act as blocking cells which 'desired result `is obtained in a very cells 30e, 30b and l30c rare conducting ce'llsliand Aarefin .the load relaycoil circuit, whereas the cells 31,31bfantl prevent energization Aof the 'load relay coil from :the battery '1'4 when the load relay contacts 15 and 16 have been closed.

Figs. 8 and 10 are graphs in which the curves 87 and `88 represent the wave form of the energizing current ob- 'tained in theload yrelay coil 41 in the generating systems and 86, respectively. 'The curves 87 and 88 have been plotted in the same manner as the curve 77 of Fig. 3, but have a somewhat different form because of the different lvoltage values etective in the load relay coil :during different portions of'the cycle of operation of the alternator 11. f

YFrom the raccompanying drawings and theforegoing detailed description, `it will -now be readily understood that this invention provides analternator-rectifier generatingvsystem of a kind suitable for use on'a vehicle 'and in which energization of the load relay `,magnet coil-iis obtained from the alternator, such that the load relay is under the control of ithe alternator and `such :that -vthis practical .and inexpensive manner by kconnection of the load relay magnet coil circuit with phase windings ofthe alternator through control resistors external load circuit.

Although the generating systems of the present-invention have `been illustrated and described herein ,to a somewhat detailed extent,.it will be understood, of course, that the invention'is not to be regarded as being `limited correspondingly in scope, but'includes all changes z-and modifications coming within the terms of the vclaims hereof.

Having thus described my invention, I claim:

l. In an alternator-rectifier generating system, an talternator, a power rectifier, an external direct-currentfload circuit connected with said alternator through said power rectifier and `including a storage battery to be charged, a load relay having a magnet coil and series switch'contacts controlling said load circuit, said contacts being normally open and adapted to be closed in response to energization of said magnet coil, resistor means, and circuit means connectingsaid magnet coilwith .saidalternator through said resistor means and one portionfof said rectifier for causing automatic closing of said switch .contacts in response to operationrof the alternator, 4the remaining portion of said rectifier being effective to prevent energization of said magnet coil from said -battery through said switch contacts when the latter have'been closed by the action of said alternator.

2. In an alternator-rectifier vgenerating system, an alternator having threefphase inductor windings, a threephase full-wave power rectifier connected with said phase windings and having direct-current load terminals,y an external direct-current load circuit connected with 4said load terminals, a load relay having a magnet coil and series switch contacts controlling said load circuit, said contacts being normally open and adapted to be closed in response to energization of said magnet coil, control resistors, and circuit means connecting said magnet coil with phase windings of the alternator through said control resistors and through portions of said power rectifier for causing such energization of said magnet coil and closing and opening of said contacts in response to operation of the alternator.

3. In an alternator-rectifier generating system, a poly phase alternator having inductor phase windings, a power rectifier having direct-current load terminals, an external direct-current load circuit connected with said load terminals, a load relay having a magnet coil and series is being driven,

' said one common terminal switch contacts controlling said load circuit, said contacts beingnormally open and adapted to be closed in `responseito energization of said magnet coil, a plurality kof control resistors, and circuit means connecting one end of said magnet coil directly with one of said load termif current load terminals and comprising three circuit arms in parallel and containing rectifier cells, said alternator having inductor phase windings connectedwith the respective circuit arms of said power rectifier, an external direct-current load circuit connected with said load terminals and including a storage battery, a load relay hav- .ing .a magnet coil and series switch contacts located in and controlling said load circuit, said rswitch contacts being normally open and adapted to be closed in response to energization of said magnet coil, control resistormeans y' comprising a plurality of resistor elements, andcircuit means connecting said magnet coil for energizationY from said alternator with said magnet coil in series circuit with -said phase windings and said resistor elements through' certain of the cells of said rectifier when said alternator other cells of said rectifier being effective as blocking cells to prevent energization of said magnet coil from said battery when said switch contacts khave `been closed` while the alternator is not being driven or whenever the battery terminal voltage exceeds the alternator output voltage available at said load terminals.

5. In an alternator-rectifier generating system, a polyphase alternator having inductor phase windings, a multiple-cell power rectifier having direct-current load terminals, an external direct-current load circuit connected -with said alternator through said power rectifier, a load relay having a magnet coil and series switch contacts controlling said load circuit, said switch contacts being normally open and adapted to be closed in response to energization of said magnet coil, control resistor means comprising a plurality of resistor elements disposed in parallel and having a common terminal on one side thereof and on the other side thereof having individual terminals connected with one of said load terminals through phase windings of said alternator and through certain of the cells of said rectifier, and circuit means connecting onel end of said magnet coil with said common terminal land the other end with said one of said load terminals.

6. An alternator-rectifier system as defined in claim in which said control resistor means consists of two resistor elements in parallel having one common terminal on one side thereof and on the'other side thereof having two individual terminals respectively connected with two of the phase windings of said atlernator, said magnet coil being connected incircuit with said alternator by having one end thereof electrically connected with and its other end electrically connected with said one direct-current load terminal through phase windings of the alternator and through certain cells of said rectifier.

a three-r ;phase alternator, a full-wave power rectifier having direct- 7. An alternator-rectifier system as Adefined in claim 5 .in which said control resistor means consists of' two resistorelements in parallel'having one common terminahon one side thereof and on the other side thereof having two individual terminals 'respectively connected with two of the phaselwindingsv of said alternator, said magnet coil Abeing connected in circuit with said alternator by having oneendfthereof electrically connected with said one common terminal and its other end electrically connected with said one direct-current load terminal through phase windings of the alternator and through certain cells of said rectifier, said load circuit including a battery to be charged, certain of the cells of said vrectifier being included in the magnet coil circuit as conductingcells when said alternator is being driven and other cells of said rectifier being blocking cells which prevent energization of said magnet coil from said battery when said switch contacts have been vclosed while the alternator is not being driven or whenever the battery terminal voltage exceeds vthe alternator output voltage available Aat said load terminals.

8. In an alternator-rectifier generating system, a threephasealternator having inductor windings for the respective phases, a full-wave power rectifier having=direct current terrninalsfand comprising connected circuit arms each containing two rectifier'cells, said phase windings being connected vwith saidcircuit arms at junction points located between the rectifier cells thereof, an external direct-current load'jcircut connected with said alternator through said power rectifier,` a load relay having va magnet coil and series switch contacts located in and controlling said load circuit, said switch contacts being normally open and adapted to be closed in response to energization-of said magnet coil, control resistor means comprising threeresistor elements disposed in parallel and having a common terminalon one side thereof and on the other side thereof `having individual terminals, circuit means connecting said individual terminals with one of said load terminals through phase windingsv of said alternator and through the rectifier cells located on one side of said junction points, and circuit means connecting one end of said magnet coil withsaid common terminal and the other end with said one of said load terminals.

9. A generating system as defined in claim 8 in which the load circuit includes a battery `to be charged, andin which the cells of said rectifier located on the other side of said junction points are blocking cells which prevent energization of said magnet coil from said battery when said switch contacts have been closed. Y References Cited in the tile of this patent UNTTED STATES PATENTS 2,520,689 Niemi Aug. 29, 1950 2,646,543 Gilchrist July 2l, 1953 2,651,749, Weber Sept. 8, 1953 FOREIGN PATENTS 608,856 Great Britain Sept. 22, 1948 110,548 1940 Australia May 7. 

